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Solution Brief

Manufacturing Plant Flexibility with Virtual Design & Validation


Manufacturing has traditionally been designed around throughput scale. Companies have invested billions of dollars in manufacturing plant facilities designed to produce billions of units of goods as rapidly and efficiently as possible.

Today, businesses are faced with increasing stock-keeping unit (SKU) numbers, the necessity for multi-product facilities, and the need to swiftly introduce new products – all of which are creating a critical need for increased flexibility in production facility design. Are today's manufacturing plants ready for this?

The rising need for flexible manufacturing planning through digitalization

As global demand for new product variants and more sophisticated products grows, optimizing a manufacturing environment for a new product prior to launch has become increasingly crucial and difficult. Leaders must recognize that, in order to match contemporary market dynamics, flexibility throughout the industrial landscape is just as vital as operational efficiency at any given unit. Today's infrastructure is designed with the goal of improving cost, efficiency, and dependability at the plant level rather than system adaptability and repeatability. Companies must adopt new tools and techniques to digitally design and validate production assets in order to be adaptable enough to win in the future.

The benefits of virtual design and validation for factory plants, lines, and equipment

Virtually designing and validating flexible lines with modular equipment and contemporary technology decreases the risk, cost, and startup time associated with manufacturing modifications. Companies will be able to easily adjust to variable demand in current and new facilities. Additionally, virtual design and validation will allow for greater flexibility in strategically introducing new equipment and capabilities with the knowledge that they will work when installed without downtime. Furthermore, they can test as many scenarios as needed in advance in a risk-free environment to generate the optimum design not only for throughput but also for factors such as energy efficiency. Organizations get the ability to predict requirement validation and compliance from nation to country. Eliminating the need to revalidate at each plant could save up to six months in the introduction of a new global product.